Section 4 – Flat-top Chain Drive Componentsmiccolucent.net/wp-content/uploads/2015/01/TSplus-Flat...Flat-top Chain Drive Component 4-0 Bosch Rexroth Corporation TSplus Assembly Conveyors

Flat-top Chain Drive Component

TSplus Assembly Conveyors 8981 500 269 08/14Bosch Rexroth Corporation04-

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Section 4 – Flat-top Chain Drive Components

TSplus flat-top chain drives are the most versatile of the three conveying media that Bosch Rexroth offers. Drives and returns can be linked together end-to-end to create extended conveyor lines of almost any length. The side flexing flat-top chain allows you to utilize in-line, serpen-tine, carousel or a mix to meet just about any assembly requirement. Drive units are available in standard and heavy duty models.

All modules offer various electrical options and motor mounting positions.

Flat-top Chain Drive components in this section can be configured into any of the basic line layouts below.

Drive

Drive

Return

Return

DriveReturnDrive

Drive

Return

Return

RectangularLinear Parallel

Over/UnderSerpentine In-line Curved

Drive(over)

Drive(under)

Return(under)

Return(over)

Drive

Drive Return

Return Drive

Drive

Return

Return

VT2 VT2

Bosch Rexroth Corporation8981 500 269 08/14 TSplus Assembly Conveyors

Flat-top Chain Drive Component

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AS2/C Standard Flat-top Chain

Drives 4-2 to 4-3

AS2/C-H Heavy Duty Flat-top Chain

Drives 4-4 to 4-5

ST2/C, CRV2/1, CRV2/2 Straight and Curved Conveyor

Sections 4-9 to 4-13

ST2/C-W Maintenance, Module and Flat-top Chain

Tools 4-16

300 500

GT2/C Flat-top Chain

4-14

LU2Chain Lubrication –

Automatic 4-6

LU2Chain Lubrication –

Manual 4-7

UM2/C Return Units

4-8

Flat-top Chain Drive Components


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Ordering Information for AS2/C

Flat-Top Chain Drive ModuleModel AS2/C

300

Motor Position

270

180

90

0

Outboard MountedMotor Orientation

PalletFlow

PalletFlow

R

M

L

This drive module in conjunction with a return module pulls flat top chain along straight or curved conveyor sections, and provides the flexibility to create rectangu-lar, serpentine or in-line curved configura-tions. The AS2/C is available with either an outboard-mounted or mid-mounted gearmotor. The outboard-mounted option (left or right side) is available in widths from 160 mm to 1040 mm, while the mid-mounted option is available in widths from 320 mm to 1040 mm. Both styles include automatic chain tensioners.

Select the mid-mounted option when space prohibits a side mounted configura-tion. The side mount, however, is gener-ally preferred for accessibility–particularly for lines with multiple conveyor sections end-to-end.

Ordering parameters allow you to specify the motor voltage, frequency, conveyor speed, and motor mounting angle (out-board-mounted drives only). Outboard-mounted drive units are delivered with the motor in the customer-specified orienta-tion, but can be rotated to any of the four positions as shown. All gearmotors include CE compliant wiring terminals.

The AS2/C drive module includes hardware required to mount it to a chain conveyor section, as well as fasteners to connect drives and returns end-to-end. For non-standard widths, speed, or voltages, please contact our applications engineering department.

NOTE: In addition to a visual inspection of chain stretch via the tensioner indica-tor, chain stretch can also be sensed with proximity switches. An SH2/UV proximity switch bracket and 12 mm barrel proxim-ity switch can be mounted to the drive castings. Two proximity switches and two brackets are required per drive. See Section 17 for proximity switch ordering information.

__________M/min

__________mm

160, 240, 320, 400,480, 640, 800, 1040

Motor Voltage/Frequency ________ V _______Hz

Motor Orientation †(outboard mount only)

See Table 4-1

_____________0°, 90°, 180°, 270°

__________mmDrive Unit Width (B)*

Motor Position

9, 12, 15, 18Nominal Speed**

** Full load conveyor speeds vary depending on motor frequency. See Table 4-1

L, M, or R

* 160 & 240 (B) only available with L or R motor positions

† 90°, 180°, & 270° motor orientations are only available with L or R motor positions

Your Choices are:

Part Number3842 998 038

Specify part number, then select from the options below. Your selection:

VFD-Ready



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Technical data for AS2/C drives

Dimensional data for AS2/C

Electrical data for AS2/C

Ordering Information for AS2/C

Table 4-1

*** Maximum payload decreases when pulled through curves. Consult Bosch Rexroth Corporation for details.

Note: Electrical Data for reference only. Refer to motor name plate for actual amperage ratings.

135

140

400

60

70

5982

.570

280

360Drive Width (B)

375

164

240

40

7

247

B+

2

B +

40

B +

181.

5

140 40

Max. Load = 300.0 kg

Max. Length F

FF

= 30.0 meters

Nominal conveyor speed = See Table 4-1 Permissible loading weight = 300 kg*** Maximum conveyor unit length = 30 m (100 ft) Motor RPM at 50 Hz = 900-1410 Motor RPM at 60 Hz = 1080-1692 Motor electrical specifications = See Table 4-1

Nom.M/min

9121518

HP3/81/21/23/4

208/60HPAMPS

240/60 380/50 415/50 480/60

3/85/85/87/8

575/60

Full Load Amps/HP @Actual Speed

50 Hz

7.99.9112.616.4

60 Hz

9.511.915.119.7

AMPS AMPS AMPS AMPS AMPSHP HP HPHP1.62.42.43.2

1.62.42.43.2

0.81.21.21.6

0.81.21.21.7

3/81/21/23/4

3/81/21/23/4

3/81/21/23/4

0.81.21.21.7

3/85/85/8

3/4

0.71.01.01.0



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This drive module uses a larger gear-box and motor in conjunction with a return unit to pull the flat-top chain along straight or curved conveyor sec-tions giving you the flexibility to create rectangular, serpentine or in-line curved configurations. The AS2/C-H is avail-able with either an outboard-mounted or mid-mounted gearbox and motor. The outboard-mounted option (left or right side) is available in widths from 160mm to 1040 mm, while the mid-mounted op-tion is available in widths from 320 mm to 1040 mm. Both styles include automatic chain tensioners.

Select the mid-mounted option when space prohibits a side mounted con-figuration. The side mount, however, is generally preferred for accessibility–par-ticularly for lines with multiple conveyor sections end-to-end.

Ordering parameters allow you to specify the motor voltage, frequency, conveyor speed, and motor mounting angle (out-board-mounted drives only). Outoard-mounted drive units are delivered with the motor in the customer-specified orientation, but can be rotated to any of the four locations, as shown. All motors include CE compliant wiring terminals.

The AS2/C-H drive module includes all of the required mounting hardware. For non-standard widths, speed, or voltages please contact our applications engineer-ing department.

Heavy Duty Flat-top Chain Drive Module Model AS2/C-H

Ordering Information for AS2/C-H

500

Motor Position

270

180

90

0

Outboard MountedMotor Orientation

PalletFlow

PalletFlow

R

M

L

Note: In addition to a visual inspection of chain stretch via the tensioner indicator, chain stretch can also be sensed with proximity switches. An SH2/UV proxim-ity switch bracket and 12 mm barrel proximity switch can be mounted to the drive castings. Two proximity switches and two brackets are required per drive. See Section 17 in the TSplus catalog for proximity switch ordering information.

__________M/min

__________mm

160, 240, 320, 400,480, 640, 800, 1040

Motor Voltage/Frequency ________ V _______Hz

Motor Orientation †(outboard mount only)

See Table 4-2

_____________0°, 90°, 180°, 270°

__________mmDrive Unit Width (B)*

Motor Position

9, 12, 15, 18Nominal Speed**

** Full load conveyor speeds vary depending on motor frequency. See Table 4-2

L, M, or R

* 160 & 240 (B) only available with L or R motor positions

† 90°, 180°, & 270° motor orientations are only available with L or R motor positions

Your Choices are:


Specify part number, then select from the options below. Your selection:



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Technical data for AS2/C-H

Nominal conveyor speed = See Table 4-2Permissible loading weight = 500 kg***Maximum conveyor unit length = 30 m (100 ft) Motor RPM at 50 Hz = 1390-1410Motor RPM at 60 Hz = 1660-1700 Motor electrical specifications = See Table 4-2

FF

FMax. Length = 30.0 meters

Max. Load = 500.0 kg

Table 4-2

Dimensional data for AS2/C-H

Electrical data for AS2/C-H

*** Maximum payload decreases when pulled through curves. Consult Bosch Rexroth Corporation for details.

Note: Electrical Data for reference only. Refer to motor name plate for actual amperage ratings.

B+

40B+

210

5

70

B+

181.

5

280Drive Width (B)

40

R

470

360

375

40

240

470

7

70

Nom.M/min

9121518

HP1/23/41.01.0

208/60HPAMPS

240/60 380/50 415/50 480/60

1/23/41.01.0

575/60

Full Load Amps/HP @Actual Speed

50 Hz

9.711.7614.0716.97

60 Hz

8.111.5914.3

16.86

AMPS AMPS AMPS AMPS AMPSHP HP HPHP1.93.03.83.8

1.83.03.83.8

1.61.62.22.2

0.821.62.22.2

1/23/41.01.0

3/43/41.01.0

3/43/41.01.0

1.61.62.22.2

3/41/2

1.01.0

0.711.21.71.7



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Automatic Chain Lubrication Module Model LU2

The LU2 automatic lubrication module provides continuous and maintenance-free lubrication for all TSplus flat-top chain and roller chain medias. The LU2 module can be used with both mainline conveyor and transverse conveyor sections. Drive specific adapter sets ensure the optimum amount of lubri-cation is applied directly to the chain links. The module requires a 24V dc power supply. Depending on the section length and chain type, the power supply must be cycled at intervals be-tween 1 and 12 hours, with a 15 second off time minimum. The metering process is controlled by an external PLC.

One LU2 module, one AS adapter set, and one LC2 oil cartridge are required for each drive. The LU2 module includes the lubrication unit, hoses, fittings, and all mounting hardware. Drive adapter sets and oil cartridges must be ordered separately.

LU 2

LC 2

Set AS ...

00000003

85 148

158

341

Description Part Number

LU2 Automatic Lubrication Module 3842 543 482

LC2 Oil Cartridge – 0.25L Kluber Structovis GHD, lot size 4

3842 543 469

Adapter Set (for BS2/C, BS2/C-H) 3842 543 483

Adapter Set (for AS2/C, AS2/C-H) 3842 543 484

Adapter Set (for BS2/R, BS2/R-H) 3842 543 485

Adapter Set (for AS2/R, AS2/R-H) 3842 543 486

Adapter Set (for AS2/R Vplus, AS2/R-H Vplus) 3842 543 487

Ordering Information for Automatic Chain Lubrication Module

Dimensional data for LU2 Automatic Chain Lubrication Module



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Manual Chain Lubrication – Drill Fixture

As an alternative to lubricating chain automatically with the LU2 module, flat-top and roller chains can also be lubricated manually.

The chain lubrication drill fixture is used for drilling an 8mm diameter access hole for manually lubricating chain in the return channel of the conveyor section.

The drill fixture is compatible with ST2/C-100, ST2/C-H, ST2/R-100, ST2/R-H, and ST2/R Vplus conveyor section.

Chain oil is ordered separately.


Manual Chain Lubrication Drill Fixture R980 025 504

Oil Cannister – 0.5L Kluber Structovis GHD, lot size 1 0842 904 229

Ordering Information for Manual Chain Lubrication Drill Fixture and Oil

Dimensional data

ST2/C-100Conveyor Section 3842 994 890

ST2/R-100Conveyor Section 3842 994 889

ST2/C-HConveyor Section 3842 994 973

ST2/R-HConveyor Section 3842 994 972



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Flat-top Chain Return Unit Model UM2/C-60 UM2/C-170

A return unit is required for each in-line drive unit to direct or “return” the continuous loop of chain from the center channel in the conveyor rail back up to the transport level. All hardware needed to mount the return units to a conveyor sections is included.

The UM2/C-60 returns use a sliding block to return the chain to the top of the system. This return is designed for conveyor sections up to 6000mm long.

The UM2/C-170 returns use a sprocket to return the chain to the top of the system. This return is recommended for conveyor sections over 6000mm long

Description

Ordering Information for Return Unit UM2/C

Return Unit UM2/C-60 (qty. 2) 3842 528 802 Return Unit UM2/C-170 (qty. 2) 3842 528 806

Part Number

Dimensional data for UM2/C Return Units

70

20

100

7 170 B+2

70

Ø8.4 mm

62

16

710

0

60 B+2

Ø8.4 mm

UM2/C-60 UM2/C-170

UM2/C-170

UM2/C-60

NOTE: Refer to the connection kits on page 9-3 to mount a UM2/C end-to-end to an AS2, BS2 or KE2.



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Description Part number

Flat-top chain ST2/C–100 3842 994 890/...

The conveyor section is the structural element that supports and guides the workpiece pallet. Each section consists of two anodized aluminum chain profiles (SP2/C), with upper/lower slide profile (GP2), and plastic guide profile (FP2) in-stalled. The installed slide profiles serve as wear strips and as a bearing surface for the chain. Order cross connectors separately on page 7-1.

The 10 mm T-slot in each side and bot-tom of the aluminum chain profile allows conveyor modules or peripheral devices to be mounted using T-bolts or T-nuts, eliminating the need for special machin-ing.

Maximum chain section length is 6000 mm, however, Rexroth will custom cut at no charge straight conveyor sections in 1 mm increments, from 200-6000 mm. To order conveyor sections, add the length (in mm) required for your system onto the part number.

Straight Flat-top Chain Conveyor SectionsModel ST2/C–100

Ordering Information for Conveyor Sections ST2/C–100

* To order conveyor sections 200-6000 mm long, please specify desired length at the end of the part number. For example, to order a 2000 mm conveyor section, your part number should look like this: 3842 994 890/2000.

B = nominal conveyor width

Chain sections can be connected end-to-end with connection links to extend the conveyor length (see page 7-1). See page 4-10 for 90° and 180° curved conveyor sections.

Note: Since leg sets are required at mini-mum 2 m intervals we stock standard pre-cut 2000 mm sections for quick delivery.

Dimensional data for ST2/C–100

FP2

GP2

SP2/C

Length

B+1

B+2 mm

5

B-75

10 20

40

100

106.

5

45



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Curved Flat-top Chain Conveyor SectionsModel KU2/O-90, KU2/O-180

Curved conveyor sections are used to construct serpentine and carousel style conveyor configurations. They are avail-able in both 90° and 180° sections as shown. The outside radius of the curve varies according to the dimensions of the workpiece pallet used in the system.

Curved sections are available for line widths from 160 to 1040mm and the inner, outer and return chain guides are installed. Order legsets separately as required from page 8-1.

NOTE: Pallet repeatability cannot be maintained in a curved section. In addi-tion, pallet stopping and queuing is not allowed in curved sections.

Ordering Information for KU2/O–90 CurveSpecify part number,then select from the options below.

YourChoices are:

Part NumberR980 999 268

Pallet Width (BWT) in mm *160, 240, 320, 400480, 560, 640, 720, 800, 880, 960, 1040

__________mm

Pallet Length (LWT) in mm *160, 240, 320, 400480, 560, 640, 720, 800, 880, 960, 1040

__________mm

* See technical data table for allowable pallet width (BWT) and pallet length (LWT) combinations.

Specify part number,then select from the options below.

YourChoices are:

Part NumberR980 999 269

Pallet Width (BWT) in mm *160, 240, 320, 400480, 560, 640, 720, 800, 880, 960, 1040

__________mm

Pallet Length (LWT) in mm *160, 240, 320, 400480, 560, 640, 720, 800, 880, 960, 1040

__________mm

* See technical data table for allowable pallet width (BWT) and pallet length (LWT) combinations.

Ordering Information for KU2/O–180 Curve

KU2/O-90

KU2/O-180



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OuterGuide

InnerGuide

600

A+R+45

A+R+45

R

A

Bwt

A

OuterGuide

InnerGuide

200

100

600A+R+45

R

A

A

290+(2xR)Bwt

Dimensional data for KU2/O-90, KU2/O-180KU2/O-90

90° Chain Section

KU2/O-180

180° Chain Section

Workpiece pallet size in mm

Dimensions in mm(see diagrams below)

Chain req'd. in meters (order on page 4-14)

Width(B WT)

Length (L WT ) A R 90°

section90°

section180°

section

160

160 240

730

6.4 11.6240320 400 8.0 12.8400480 480 8.4 13.4

240

240 240

8106.6 12.0

320 400400 8.6 13.8480 480

320

320 320

890

8.6 13.8400 480 8.8 14.4480560 640 10.6 15.6640

400

400 480

970

9.2 14.8480560 640 10.8 16.2640720 800 12.4 17.4800

480

480 480

1050

9.4 15.4560 640 11.0 16.6640720 800 12.6 18.0800

Workpiece pallet size in mm

Dimensions in mm(see diagrams below)

Chain req'd. in meters (order on page 4-14)

A R 180°section

560

560 640

1130

11.2 17.2640720 800 13.0 18.4800880 880 13.2 19.0

640

640720

1210

13.2 19.0720800

880 13.4 19.6880960

1040 15.2 20.81040

720

720800

1290

13.4 19.4800880

960 14.0 20.89601040 1040 15.4 21.4

800

800880

137014.0 20.6

880960

1040 15.6 21.81040

880880

9601450

14.6 21.89601040 1040 15.8 22.4

960960

1040 1530 16.2 22.81040

1040 1040 1040 1610 16.4 23.4

Width(B WT)

Length (L WT )

Technical data for KU2/O-90, KU2/O-180



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H.D. Straight Flat-top Chain Conveyor SectionsModel ST2/C-H

The conveyor section is the structural element that supports and guides the workpiece pallet. Each section consists of two anodized aluminum chain profiles (SP2/C-H), upper/lower slide profile (GP2), and steel guide profile (FP2), installed. The installed slide profiles serve as wear strips and as a bearing surface for the chain. Order cross links separately on page 7-1.

The H.D. flat-top chain conveyor section is designed for use with standard, antistatic, and steel flat-top chain. It is available with either steel or plastic slide profile.

The H.D. flat-top chain conveyor mounts to standard AS2/C drive and UM2/C return modules.

NOTE: Adapter plates (3842 536 801) must be used to connect the ST2/C-H to an AS/C drive and a UM2/C return.

The 10mm T-slot in each side and bottom of the aluminum chain profile allows con-veyor modules or peripheral devices to be mounted using T-bolts or T-nuts eliminat-ing the need for special machining.

The ST2/C-H section also includes an in-tegrated cable duct on the outside of the profile. This cable duct can be covered with standard 10mm Cover Strip from the Rexroth structural framing product line.

Maximum chain section length is 6000 mm, however, Rexroth will custom cut at no charge straight conveyor sections in 1 mm increments from 200-6000 mm.

Chain sections can be connected end-to-end with connection links to extend the conveyor length (see page 7-1).

Length

Adapter Plates Ordered Separately

FP2 SP2/C-H

GP2

Adapter Plates Ordered Separately

5 mm

Specify part number,then select from the options below.

YourChoices are:


Conveyor Section Length (L) in mm 200 to 6000 mm(in 1 mm increments) __________mm

Slide Profile (GP2) Plastic (GP2/H-Kst)*Steel (P2/H-St) ______________

______________Attachment Location (AO)0 (intermediate)

1 (end-to-intermediate)2 (end-to-end)

Adapter Plate Kit (set of 4) 3842 536 801

Ordering Information for ST2/C-H Conveyor Section

*NOTE: In order to capture and prevent movement of the plastic slide profile (GP2) inside the conveyor section, it can only be used in an end-to-end configuration (AO = 2).



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B+2

B+25

B-75 50

22.5

10

20

60

40

1 0 7

47

25

Cable Duct

Intermediate (0)

ASDrive

UMReturn

End-to-End (2)

ASDrive

UMReturn

End-to-Intermediate (1)

ASDrive

UMReturn

(0)

A0

(1)

5

(2)

5 5

Dimensional data for ST2/C-H

Attachment locations (AO) for ST2/C-H Conveyor Sections



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Flat-top ChainModel GT2/C

Flat-top chain is #40 type with extended link pins. It is available in 6 and 12 meter rolls. Flat-top chain is available in three styles- standard, steel and antistatic.

NOTE: Antistatic and steel chain can-not be used in curve sections.

Snap-on, wear-resistant caps cover each link. See page 4-16 for flat-top chain as-sembly and disassembly tools. Each roll includes one master link with a white cap for easy visual identification.

Additional master links and accompany-ing white caps for flat-top chain may be ordered separately.

On straight conveyor sections use the formula, the ordering table, and cor-responding diagram to determine how much chain you will need.

For assistance calculating quantity of chain required, please contact the Bosch applications engineering department.

Ordering Information for Flat-top chain GT2/C

Flat-top chain

Cap Chain 3.2

12.7 31.8

Dimensional data for GT2/C

Standard Flat-top Chain Part Number

6 m roll 8981 022 169

12 m roll 8981 022 170

Antistatic Flat-top Chain

12 m roll 3842 535 327Components

Master link 8981 022 172

Master link replacement cap (white) * 8981 022 173Standard replacement cap (black) * 8981 022 174

*Note: Replacement caps are non-conductive

Additional Master Link



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Calculating chain requirements:

length= 1000 mm Minimum conveyor section

Return DriveL

For In-line Straight and Curved For Carousel Conveyors

(Number of drives) x (3,000 mm) ______mm(Number of curves) x (chain required table on 4-11) ______mm(4 x L) (L= length of the straight chain section) ______mm

Total chain required* ______mm

Minimum length = 300 mm

Return DriveL

For BS2/C Transverse Conveyors

[(L - 234)x4] + 1070 = Total chain required* ______mm

* This number includes the total chain required for both conveyor sections including drives and returns.

** This number includes the total chain required for both conveyor sections including the carousel drive.

L2=L1–12501250

L 3

L1

Drive

Straight Conveyor Section

(Number of drives) x (7,112 mm) ______mm ______mm ______mm ______mm

(Number of curves) x (chain required see table pg. 4-11) ((L1 + L2) x 2) + (L3 x 4)*

Total chain required**

Note: Divide the total chain required above by 12,000 to determine the number of 12 m rolls to order.



4

ChainAssembly

ToolChainbreaker

Flat-top Chain Tools

Use the flat-top chain assembly and dis-assembly tools when adding or removing links from the flat-top chain conveyor.

The chain breaker tool presses out the pins from the chain allowing you shorten and rejoin the chain using a master link.

The chain assembly tool presses the pin link into the link plate of the maser link when joining the ends of flat-top chain.

DescriptionFlat-top chain break tool

Flat-top chain assembly tool


8981 010 650

Flat-top Chain Maintenance Module Model ST2/C-W, ST2/C-W-H

The ST2/C-W maintenance module is designed to be used with ST2/C-100 straight conveyor sections and provides an access point for assembly, disassem-bly, or lubrication of a flat-top chain con-veyor section. This module is specifically for use with flat-top conveyor sections (ST2/C-100 pg. 4-9 only).

The ST2/C-W-H maintenance module is designed to be used with ST2/C-H straight conveyor sections and provides an access point for assembly, disas-sembly, or lubrication of a flat-top chain conveyor section. This module is specifi-cally for use with H.D. flat-top conveyor sections (ST2/C-H pg.4-12 only).

The maintenance module consists of two 400mm long sections. Each section includes two removable, electrically con-ductive side covers. Connection links are used to mount each maintenance module to the conveyor sections.

All mounting hardware is included.


ST2/C-W Maintenance Module 3842 532 777

ST2/C-W-H Maintenance Module 3842 537 310

Ordering Information for ST2/C-W Maintenance Module

Dimensional Data for ST2/C-W, ST2/C-W-H Maintenance Module

00116764.eps

400 mm

Use only with ST2/C-100 (pg. 4-9) and ST2/C-W-H

(pg. 4-12) Straight Conveyor Sections

Documents

Section 4 – Flat-top Chain Drive Componentsmiccolucent.net/wp-content/uploads/2015/01/TSplus-Flat...Flat-top Chain Drive Component 4-0 Bosch Rexroth Corporation TSplus Assembly Conveyors